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12.0
Assembly of split cast-iron block using Viessmann
draw tool
12.1
Section block assembly (see Figs. 10, 27, 28, 29, 30)
Depending on the boiler size, the cast-iron section
assembly is shipped in pre-assembled blocks of two or
more. Site assembly of the blocks is required and the
following procedure must be strictly adhered to.
1)
Remove the boiler tie rods from boiler block;
individual section blocks come apart, remove the
rubber shipping washers. See Fig. 27.
2)
Remove the threaded flanges from end sections.
See Fig. 27.
3)
Ensure return water distribution tube and 5-point
well are removed from cast-iron block. See Figs.
10, 27a.
12.2
Cleaning
1)
Carefully clean the sealing grooves and the cast-
iron push nipples with extra fine emery cloth.
Important: The above cleaning procedure is
required to remove all rust and/or foreign material
that may have collected. Do not score the nipples
or sealing grooves by over-cleaning.
2)
Using a narrow putty knife, trowel the sealing
compound provided carefully into the sealing
grooves. Make sure that the complete groove
system on each section block is completely filled
with the sealing compound. Failure to fully seal
each section block will result in flue gas leaks.
3)
Carefully clean the smooth machined surfaces of
the nipple ports assuring they are clear of all
grease, metal cuttings and other debris. If
necessary, use the extra fine emery cloth to
carefully remove surface rust build-ups. Apply push
nipple lubricant to all surfaces of the nipple ports
and tapered push nipples.
4)
Ensure that the push nipples are evenly inserted
into the nipple ports, top and bottom. Place a wood
block across the nipple and gently tap the wood
until the nipple is securely in place. The nipple must
be inserted absolutely straight into the nipple port.
Apply force from your hammer evenly on the full
rim edge of the nipple. Use a tape measure to
ensure that the nipple is uniformly inserted.
Note: The above procedure is intended to only
locate the nipple securely in place. Do not apply
excessive force when setting the nipples in place.
30
Fig. 27
Vertical outlet
Horizontal outlet
Gasket
Return flange
Fig. 27a
Water distribution tube – boiler return
Fig. 28
Boiler
casting
Gasket
Water distribution pipe
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